Form P6567

Edition 10
February 2006
CCN: 03531480

Starters
Series SS815, SS825 and SS850

Installation and
Maintenance Information

Save These Instructions

 WARNING
General Product Safety Information
• Read and understand this manual before operating this tool.
• It is your responsibility to make this safety information available to others that will operate this Starter.
• Failure to observe the following warnings could result in injury.

WARNING
• For safety, top performance, and maximum durability of parts, do not operate SS815, SS825 and SS850 Series
Starters at air pressures over the pressure rating stamped on the nameplate. Use supply lines of adequate size as
directed in the installation instructions in this manual.
• Always turn off the air or gas supply and disconnect the air or gas supply hose before installing, removing or
adjusting any accessory on this starter, or before performing any maintenance on this starter.
• SS815, SS825 and SS850 Series Starters are designed for gas operation. They are not totally sealed in dynamic
operation since the exhaust must be vented or piped away and there is a possibility of leakage around the output
shaft when rotating.
• Caution should be taken when operating these starters on gas because of the danger of fire, explosion or inhalation.
After assembling a starter, always test it in accordance with the procedures outlined in this manual. Never install a
reassembled starter that has not been tested in accordance with the procedures in this manual.
• Operate this starter only when properly installed on the engine.
• Do not lubricate starters with flammable or volatile liquids such as kerosene or jet fuel.
• Always wear eye protection when performing maintenance on this Starter.
• Always wear hearing protection when testing this Starter.
• Do not use damaged, frayed or deteriorated air hoses and fittings.
• Do not remove any labels. Replace any damaged label.
• Use accessories recommended by Ingersoll Rand.

NOTICE
• The use of other than genuine Ingersoll Rand replacement parts may result in safety hazards, decreased starter performance
and increased maintenance, and may invalidate all warranties.
• Ingersoll Rand is not responsible for customer modification of starters for applications on which Ingersoll Rand was not consulted.
• Repairs should be made only by authorized, trained personnel. Consult your nearest Ingersoll Rand Authorized Servicenter.
• It is the responsibility of the employer to place the information in this manual into the hands of the operator.

Safety Information - Explanation of Safety Signal Words

Indicates an imminently hazardous situation which, if not avoided, will result in death or
DANGER serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or
WARNING serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or
CAUTION moderate injury or property damage.

Indicates information or a company policy that relates directly or indirectly to the safety of
NOTICE personnel or protection of property.

Placing Starter in Service

NOTICE
For natural gas operation, starter main exhaust must be piped away.
To pipe the drive housing vent, remove the drive housing plug and replace it with a suitable tubing line. The tubing must
vent at a safe location and must not be interconnected with any other exhaust lines which might introduce a back
pressure on the drive housing vent.

2 03531480_ed10
Lubrication
Proper lubrication is essential for top performance and For Starter installations with cranking cycles more than 10
maximum durability of a Starter. seconds. Install as shown in Piping Diagrams. Lubricate with
a good quality 10W non-detergent motor oil. Adjust the
Two lubrication systems are recommended: Lubricator to flow 1 to 3 drops per second.

Ingersoll Rand No. HDL2 Lubricator: For Starter

installations with cranking cycles of less than 10 seconds.
CAUTION
Install as shown in Dwg. TPB978. (See Installation of HDL2 When an HDL2 Lubricator is used, make certain that the
Lubricator on page 5). Lubricate with diesel fuel or 10W oil supply line pressure is no greater than 5 psi. If there
non-detergent motor oil. is pressure on the line, the Lubricator will continuously
leak lubricant through the Starter and out of the exhaust.
Ingersoll Rand No. NL-24-8 In-Line Lubricator:

Installation
Orientation of the Air Starter
NOTICE If the factory orientation will not fit your engine due to radial
location of the Drive Housing or location of the inlet and/or
For maximum performance, read this manual prior to the
exhaust ports, reorient the Starter as follows:
installation or operation of Series SS815, SS825 and
SS850 Starters.
1. Look at the dimension illustration and note that the Drive
General Information Housing (30) can be located in any one of sixteen radial
1. We recommend that on all vehicular installations and on positions relative to the Gear Case (58). The exhaust port
stationary engines subject to vibration that hoses of the (Motor Housing) (1) can be located in any one of four
specified diameter be used instead of rigid pipe radial positions relative to the Gear Case and the air inlet
connections to the starter. Vehicle and engine vibration (Motor Housing Cover) can be located in any one of four
will soon loosen rigid pipe connections, whereas hoses radial positions relative to the exhaust port. Also, the
will absorb the vibration and connections will remain tight. Drive Housing can be installed on the engine bell housing
2. This starter is designed for flange mounting at the inlet. in any one of three radial positions.
All piping, hoses and fittings must be clean and free of
dirt and foreign material during installation. NOTICE
3. In the actual mounting of an Air Starter, it is best to have
the hose connections already made at the receiver, and Do not separate the Drive Housing from the Gear Case
to have the starter end of the hose handy for attaching to during orientation or installation.
the Starter.
4. Engine design often demands that the starter be mounted 2. Study the engine mounting requirements and determine
underneath in extremely close quarters, and even though the required orientation of the Drive Housing relative to
two of the mounting bolt holes are easy to reach, the third the Gear Case. If the Drive Housing has to be reoriented,
one is often less accessible. To install a starter, the remove the eight Drive Housing Cap Screws (28) and
following tools are required: a regular ratchet wrench, rotate the drive housing to its required position. Reinstall
sockets, universal joint, socket extension and a single or the Drive Housing Cap Screws and tighten them to
double-end box wrench. 28 ft-lb (38 Nm) of torque.
5. The efficiency of an Air Starter can be greatly impaired by
an improper hook-up. Hoses smaller than those
recommended will reduce the volume of air to the motor
NOTICE
and the use of reducers for piped-away applications in Do not separate the Motor Housing from the Motor
the exhaust port will restrict the exhaust causing back Housing Cover during orientation or installation.
pressure to the motor resulting in reduced performance.
The number of tees and elbows, and the length of the 3. Now that you have the Drive Housing properly oriented
supply line should be kept to a minimum. Use 1-1/2” #24 relative to the Gear Case, notice whether or not the
hose or pipe for supply lines upto 15 feet long; use 2” exhaust port will be at the bottom and whether or not the
hose or pipe if the supply line is over 15 feet long. inlet port will be favorably located for hose installation. If
6. A leak in any of the connections in live air lines means either or both of these members must be reoriented,
that the system will drain overnight and will have to be remove the four Motor Housing Cover Cap Screws (4)
re-pressurized the next morning by use of another vehicle and rotate the Motor Housing and/or Motor Housing
or compressor. Make your connections bubble tight to Cover to its desired position. Reinstall the Motor Housing
avoid unnecessary costs and delays. On all threaded Cover Cap Screws and alternately tighten them to 60 ft-lb
connections throughout the system, use Ingersoll Rand (81.4 Nm) of torque.
No. SMB-441 Sealant, non-hardening No. 2 Permatex or
Loctite®* Pipe Sealant. Always run your air supply line Mounting the Air Starter
from the side or top of the receiver, never at or near the 1. Study the Piping Diagram. We strongly recommend that
bottom. Moisture in the air collects at the bottom of the the Starter be connected exactly as shown.
receiver resulting in damage which could cause the 2. The air receiver tank for a Starter installation must have a
valves to become inoperative. Periodically, open the working pressure capability equal to or greater than the
petcock at the bottom of the tank to drain the water. maximum pressure at which the Starter will be operated.

WARNING
Bleed off the air pressure through a valve or petcock. Do
not remove the plug from the tank while the tank is still
pressurized.

* Registered trademark of Loctite Corporation.

03531480_ed10 3
3. If you are going to connect to a receiver tank that is 15. Install a 1/4” #4 hose line from the “OUT” port on the
already in service, bleed off the air pressure by opening Starter Drive Housing to the small pipe tapped port on top
the drain valve. Drain off any water that may have of the Starter Relay Valve.
accumulated in the bottom of the tank. 16. If the exhaust is not to be piped away, install a
No. SS660-A674 Muffler or No. SM450-A735 Road
NOTICE Splash Deflector in the exhaust port on the Motor
Housing of the Starter.
Make certain the connection between the SRV150 Starter 17. If the engine on which the Starter is mounted does not
Relay Valve and the Receiver Tank is made to the inlet have a bell housing with a standard starter mounting, and
side of the Relay Valve indicated by the word “IN” cast a bracket had to be manufactured for mounting, we
on the valve body. recommend that you add an additional support bracket at
the motor end of the Starter. There are four holes in the
4. Using a 1-1/2” short nipple, install the SRV150 Starter Motor Housing Cover for this purpose. They are tapped
Relay Valve on the end of the receiver tank as shown in M10-1.50 to accommodate metric cap screws.
Dwg. TPC444-4 on page 7. 18. Mount an HDL2 Lubricator on or near the Starter as
5. Install the No. SMB-618 Starter Control Valve on the dash shown in Dwg. TPB978 on page 5.
panel (for vehicular installations) or some other 19. Pressurize the complete starting system and check every
appropriate panel (for stationary installations). connection with a soap bubble test. There must be no
6. Attach No. TA-STR-100 Starter Instruction Label to the leaks.
control panel adjacent to the Starter Control Valve.
7. Mount the No. 150BMP-1064 Air Pressure Gauge on or Barring Over the Engine
adjacent to the control panel. It should be located where it Occasionally, for setting injectors and/or for timing purposes,
is readily visible to the operator of the Control Valve. it may be desirable to bar over the engine in such a manner
that any given piston can be stopped at any given location.
NOTICE This is very easily done with a SS815, SS825 or SS850
Starter.
When connecting the Starter Control Valve to the Relay 1. Disconnect the 1/4” #4 hose at the “OUT” port on the
Valve, make certain the hose is connected to the “SUMP” Drive Housing, and plug the hole in the Drive Housing
side of the Starter Control Valve. with a 1/4” pipe plug.
2. Remove the 3/8” pipe plug from the center of the Motor
8. Connect the Starter Control Valve to the Relay Valve with Housing Cover.
1/4” #4 hose. Install a Tee in this line with a short feeder 3. Engage the Drive Pinion with the flywheel by applying
hose to the Pressure Gauge. pressure to the “IN” port on the Drive Housing.
9. Run a piece of heavy duty garden hose, or some other 4. Insert a 3/8” square drive wrench through the hole in the
similar large diameter hose from the Relay Valve on the Motor Housing Cover to engage the square drive recess
receiver to the starter location on the engine to determine the rear of the Rotor.
the exact length of 1-1/2” #24 air hose required. 5. Manually rotate the Rotor until the engine is cranked to its
10. Attach the 1-1/2” #24 air hose to the outlet side of the desired position.
Relay Valve, and run the hose through the frame, etc. to
its final position at the starter location. The HDL2 Lubricator is self-priming and may be installed
11. At this point, determine whether or not it is practical to directly on the Starter or located remotely. Although the
attach the hose to the Starter before or after the Starter is Lubricator is capable of drawing lubricant from a source 4 ft
actually mounted. In many cases, it may be necessary to (1.2 m) lower than the point of installation, Ingersoll Rand
attach the hose to the Starter before mounting. recommends installing the Lubricator as close as possible to
12. Liberally grease the teeth on the ring gear with a good, the oil source. We recommend using the unpressurized fuel
sticky gear grease or motorcycle chain lubricant. This will return line as the source of lubricant. However, oil may be
help promote the life of the ring gear and the Starter supplied from a separate receiver or the diesel fuel tank.
Pinion. When the diesel fuel tank is the lubricant source, install a
13. Place the Starter into position and mount it on the 10 micron to 50 micron fuel filter in the oil supply line at the
flywheel bell housing. Tighten the mounting bolts to fuel tank. The lubricant supply line should be fed into the fuel
100 ft-lb (136 Nm) of torque. return line with the leg of the tee going to the lubricator
14. Install a 1/4” #4 hose line from the “DEL” side of the directed in the down direction to insure that the lubricator
Starter Control Valve to the “IN” port on the Starter Drive does not draw air instead of oil.
Housing.
INSTALLATION OF HDL2 LUBRICATOR

AIR SUPPLY HOSE

LUBRICANT SUPPLY HOSE LUBRICANT SUPPLY HOSE

TO STARTER AIR SUPPLY OR OIL CHAMBER

REMOTE INSTALLATION OF HDL2 LUBRICATOR

(Dwg. TPB978)
* Registered trademark of E.I. Dupont de Nemans and Co. Inc.

4 03531480_ed10
Mount the HDL2 Lubricator as follows: tank or separate oil reservoir. Tighten the fitting at the
Lubricator to 15 to 36 ft-lb (20.3 to 40.8 Nm) torque. The
1. If you are going to mount the HDL2 Lubricator on the
threads on the fitting must be clean; assemble it without
Starter, remove one of the 3/8” pipe plugs from the inlet
boss on the Starter and replace it with the HDL2. If you sealing compound or Teflon®* tape. Connection must be
are going to mount the HDL2 at a remote location, use vacuum tight.
two U-bolts and base clamp available for the Lubricator.
2. If you mounted the HDL2 at a remote location, install a NOTICE
1/4” #4 hose from the end of the Lubricator having both a
male and female thread to one of the 3/8” pipe tapped Before initial operation, manually fill the oil supply line.
holes on the Starter inlet boss.
4. If a separate lubrication reservoir is used, fill it with diesel
3. Install a 1/4” hose from the 1/8” NPTF oil inlet in the side
fuel or a light motor oil such as SAE 10 or 10W.
of the HDL2 to the unpressurized fuel line, diesel fuel

03531480_ed10 5
6
419.5
(16.5)
222.5
(8.8)

(Dwg. TPA1325-1)
138.5 10.5
10.0 (5.5) (.4)
REMOVE PIPE PLUG FOR (.4)
ACCESS TO 3/8 SQ. DRIVE
BARRING HOLE IN ROTOR. 1/4-18 NPT 52º 30'
152.0 CONTROL PORT
(6.0) OUTLET H I J
16.6 TYP. (0.6)
VENT PLUG G K 3-PLACES
SS825 ONLY
LUBRICATOR
CONNECTION F L
BOTH SIDES. 23.0
116.0 (.9)
(4.6) 92.00 E M
PILOT
(3.6)
R 77.5 85.7 146.0
94.5 D N
(3.1) (3.4) (5.7)
(3.7)
28.5 C O
17.5
(.7) (1.1) PINION TRAVEL
108.0 45.0 B P
A
(4.3) 1/4-18 NPT (1.8)
RING GEAR FACE
CONTROL PORT
R 86.5 INLET
(3.4) 159.5 50.8
(6.3) (2.0) LEFT HAND
120º 0'
ROTATION

2 1/2-8 NPT
Ø 172.0
(Ø 172.0) 322.0 RIGHT HAND
M10-1.5 TH'D .63 DEEP (12.7) ROTATION
(16.0) 2-PLACES 434.0
(FOR REAR SUPPORT) (17.1) NOTES:
447.7
1. STARTERS SHOULD BE INSTALLED ON THE ENGINE WITH THE
(17.6)
Mounting Dimensions for Series SS815 and SS825 Starters

ORIENTATION OPTIONS
INLET EXHAUST DRIVE HOUSING
EXHAUST POINTED DOWN.
4 @ 90º 4 @ 90º 16 @ 22 1/2º 2. USE THE SET OF CONTROL PORTS ON THE UPPER SIDE OF THE
DRIVE HOUSING.
-MODEL CODING- 3. THESE MODELS ARE NOT APPROVED FOR APPLICATIONS WHERE
THE STARTER IS EXPOSED TO THE TRANSMISSION FLUID.
SS815 G B 03 R 31- 0 2 G 4. DRIVE HOUSING ORIENTATION CODE IS BASED ON POSITION OF
MOUNTING HOLE OPPOSITE THE CONTROL PORTS.
SIZE STARTER DRIVE HOUSING 5. STANDARD ORIENTATION SHOWN (02G) WILL BE SHIPPED UNLESS
TYPE STARTER EXHAUST OTHERWISE SPECIFIED.
GEARING ORIENTATION CODE 6. PLEASE READ THE INSTRUCTIONS BEFORE ATTEMPTING TO
DRIVE HOUSING INLET REORIENT.
ROTATION TYPE PINION 7. STARTER WEIGHT = 43.1 Kg (95 lbs.)
DRIVE

DUAL MM

DIMENSIONS (INCH)

03531480_ed10
 361.5
(14.2)

03531480_ed10
168.0 180.0

(Dwg. TPA832-5)
(6.6) (7.1)

110.2
REMOVE PIPE PLUG FOR (4.3) 1/4-18 NPT 23.34
ACCESS TO 3/8 SQ. DRIVE CONTROL PORT (.9)
BARRING HOLE IN ROTOR. OUTLET 45º
10.7
(.4)

1 1/2 - 11 1/2 NPT G H I

J
K
LUBRICATOR 90º
65.2 CONNECTION TYP F
(2.6) BOTH SIDES. L
152.3 E
(6.0) M

53.2 48.2
R 43.6 D N
(2.1) (1.9) PILOT
(1.7)
O
C 17.5
20.0 B
A P (.68) TYP.
(.8)
R 64.3 3- PLACES
108.0 18.0 (2.5)
R 48.7 (4.3)
(1.9) (.7)
28.5
LEFT HAND
Mounting Dimensions for Series SS850 Starters

1/4-18 NPT (1.1)

ROTATION
CONTROL PORT
INLET RING GEAR FACE
2 1/2-8 NPT 186.5
172.0
(7.3)
RIGHT HAND
M10-1.5 TH'D 263.0
ROTATION
16.0 (.63) DEEP 2-PLACES (10.4)
(FOR REAR SUPPORT)
NOTES:
375.0 1. STARTERS SHOULD BE INSTALLED ON THE ENGINE WITH THE
(14.8) EXHAUST POINTED DOWN.
2. USE THE SET OF CONTROL PORTS ON THE UPPER SIDE OF THE
ORIENTATION OPTIONS
INLET EXHAUST DRIVE HOUSING DRIVE HOUSING.
4 @ 90º 4 @ 90º 16 @ 22 1/2º 3. THESE MODELS ARE NOT APPROVED FOR APPLICATIONS WHERE
THE STARTER IS EXPOSED TO THE TRANSMISSION FLUID.
-MODEL CODING- 4. DRIVE HOUSING ORIENTATION CODE IS BASED ON POSITION OF
MOUNTING HOLE OPPOSITE THE CONTROL PORTS.
SS850 G B 09 R 51- 0 2 E 5. STANDARD ORIENTATION SHOWN (02E) WILL BE SHIPPED UNLESS
OTHERWISE SPECIFIED.
SIZE STARTER DRIVE HOUSING 6. PLEASE READ THE INSTRUCTIONS BEFORE ATTEMPTING TO
TYPE STARTER EXHAUST
REORIENT.
GEARING ORIENTATION CODE
7. STARTER WEIGHT = 25.4 Kg (56 lbs.)
DRIVE HOUSING INLET
ROTATION TYPE PINION
DRIVE DUAL MM
DIMENSIONS (INCH)

7
Typical Vehicular Installation (Shown with SS815 Starter)
#4 HOSE STARTER CONTROL VALVE
SMB-618 (BRASS)

AIR PRESSURE GUAGE

AIR SUPPLY
TO RELAY FROM COMPRESSOR
VALVE #4 HOSE
FROM STARTER
JIC 37º
CONTROL VALVE CHECK VALVE
SRV125-1242

"IN" PORT JIC 37º ADAPTER

JIC 37º ADAPTER 1 - 1/2" N.P.T
"OUT" PORT 1/4" N.P.T.
JIC 37º ADAPTER-
1 -1/2" HOSE
1/4" N.P.T.

1 - 1/2"
N.P.T.
AIR RECEIVER
TANK

LUB. SUPPLY
LINE
AIR/GAS STARTER
PIPE PLUG
1/8"-27 PTF SRV 150-1-1/2"
SAE SOCKET DRIVE RELAY VALVE 1-1/2" PIPE

FOR NATURAL GAS OPERATION, STARTER MAIN EXHAUST MUST BE PIPED

AWAY.
NOTE:
TO PIPE THE DRIVE HOUSING VENT, REMOVE THE DRIVE HOUSING PLUG AND
USE I R SMB-441 SEALANT
REPLACE IT WITH A SUITABLE TUBING LINE. THE TUBING MUST VENT AT A SAFE
ON ALL PIPE CONNECTIONS
LOCATION AND MUST NOT BE INTERCONNECTED WITH ANY OTHER EXHAUST
AIR/GAS STARTER
LINES WHICH MIGHT INTRODUCE A BACK PRESSURE ON THE DRIVE HOUSING
SS660-A674 MUFFLER VENT.
OR SM450-A735 ROAD
SPLASH DEFLECTOR
(Dwg. TPC444-4)

Typical Stationary Installation (Shown with SS815 Starter)

STARTER CONTROL VALVE
SMB-618
AIR PRESSURE GUAGE

#4 HOSE
RELIEF VALVE SET AT 15 P.S.I.
ABOVE REGULATOR SETTING

FOR GAS OPERATING THE RELIEF #4 HOSE

VALVE OUTLET MUST BE
CONNECTED INTO A SAFE AREA.
JIC 37º ADAPTER
1/4" N.P.T JIC 37º ADAPTER
1-1/2" N.P.T

"OUT" PORT
JIC 37º ADAPTER
SRV150 1-1/2" HOSE 1/4" N.P.T.
1-1/2" RELAY VALVE
PRESSURE REGULATOR (MAXIMUM "IN" PORT
SETTING NOT TO EXCEED PRESSURE LUBRICATOR JIC 37º ADAPTER
RATING SHOWN ON NAME PLATE) NL-24-8 1/4" N.P.T.
HIGH PRESSURE SUPPLY

STANDARD HIGH PRESSURE SYSTEM

AIR OR GAS. USE WHEN SUPPLY
PRESSURE IS OVER PRESSURE
RATING OF STARTER

FOR NATURAL GAS OPERATION, STARTER MAIN EXHAUST

MUST BE PIPED AWAY.

TO PIPE THE DRIVE HOUSING PLUG, REMOVE THE DRIVE

HOUSING PLUG AND REPLACE IT WITH A SUITABLE
TUBING LINE. THE TUBING MUST VENT AT A SAFE
LOCATION AND MUST NOT BE INTERCONNECTED WITH
ANY OTHER EXHAUST LINES WHICH MIGHT INTRODUCE A
BACK PRESSURE ON THE DRIVE HOUSING VENT.

(Dwg. TPA842-2)

8 03531480_ed10
Typical Installation with Engine Prelube System

#4 HOSE

STARTER CONTROL VALVE

SMB-618
OIL PRESSURE SENSING VALVE
EXHAUST

#4 HOSE
"OUT" PORT JIC 37º
AIR PRESSURE "IN" PORT JIC 37º ADAPTER 1/4" N.P.T.
GAGE ADAPTER 1/4" N.P.T.

#4 HOSE

JIC 37º ADAPTER

1-1/2" N.P.T.
FOR NATURAL GAS OPERATION, STARTER MAIN EXHAUST MUST BE
PIPED AWAY.
1-1/2" RELAY VALVE
SRV150 TO PIPE THE DRIVE HOUSING VENT, REMOVE THE DRIVE HOUSING PLUG
AND REPLACE IT WITH A SUITABLE TUBING LINE. THE TUBING MUST
VENT AT A SAFE LOCATION AND MUST NOT BE INTERCONNECTED WITH
1-1/2" PIPE
TO PRELUBE PUMP ANY OTHER EXHAUST LINES WHICH MIGHT INTRODUCE A BACK
JIC 37º ADAPTER PRESSURE ON THE DRIVE HOUSING VENT.
1/4" N.P.T.
1-1/2" PIPE CHECK VALVE
150BMP-1054
TANK
1-1/2" PIPE (MAXIMUM PRESSURE NOT TO EXCEED
LUBRICATOR PRESSURE RATING ON STARTER
NL-24-8 NAMEPLATE) SUPPLY
#4 HOSE

STANDARD SYSTEM WITH

ENGINE PRELUBE 1-1/2" RELAY VALVE
SRV150
(Dwg. TPA843-2)

Typical Installation with Engine Prelube System when Supply Pressure is over Rated
Starter Pressure
#4 HOSE OIL PRESSURE SENSING VALVE
RELIEF VALVE SET AT 15 PSI
ABOVE REGULATOR SETTING

FOR GAS OPERATION, THE RELIEF

VALVE OUTLET MUST BE
1-1/2" RELAY VALVE CONNECTED INTO A SAFE PLACE.
JIC 37º ADAPTER SRV 150
1/4" N.P.T. LUBRICATOR
NL-24-8
1-1/2" PIPE
HIGH PRESSURE SUPPLY

JIC 37º ADAPTER

1-1/2" N.P.T. TO PRELUBE
PUMP
STARTER CONTROL VALVE AIR PRESSURE
SMB618 GAGE 1-1/2" RELAY VALVE
1-1/2" HOSE #4 HOSE SRV 150 PRESSURE REGULATOR (MAXIMUM SETTING
NOT TO EXCEED PRESSURE RATING SHOWN
ON STARTER NAMEPLATE)
#4 HOSE

"OUT" PORT JIC 37º #4 HOSE

"IN" PORT JIC 37º ADAPTER 1/4" N.P.T.
ADAPTER 1/4" N.P.T.

HIGH PRESSURE SYSTEM WITH ENGINE

PRELUBE USE WHEN SUPPLY PRESSURE IS
OVER RATING OF STARTER.

FOR NATURAL GAS OPERATION, STARTER MAIN EXHAUST MUST BE

PIPED AWAY.

TO PIPE THE DRIVE HOUSING VENT, REMOVE THE DRIVE HOUSING PLUG
AND REPLACE IT WITH A SUITABLE TUBING LINE.
THE TUBING MUST VENT AT A SAFE LOCATION AND MUST NOT BE
INTERCONNECTED WITH ANY OTHER EXHAUST LINES WHICH MIGHT
INTRODUCE A BACK PRESSURE ON THE DRIVE HOUSING VENT.
(Dwg. TPA844-2)

03531480_ed10 9
Typical Multiple Starter Installation
#4 HOSE
#4 HOSE

JIC 37º ADAPTER

"OUT" PORT JIC 37º
STARTER CONTROL VALVE 1-1/4" N.P.T.
"IN" PORT JIC 37º ADAPTER 1/4" N.P.T.
SMB-618
ADAPTER 1/4" N.P.T.
1-1/2" PIPE

1-1/2" HOSE
#4 HOSE

JIC 37º ADAPTER

1-1/2" N.P.T.

LUBRICATOR
1-1/2" RELAY NL-24-8
VALVE SRV150 #4 HOSE

#4 HOSE EXHAUST PIPED AWAY FOR GAS

OR USE MUFFLER SS660-A674 OR
DEFLECTOR SM450-A375

1-1/2" PIPE
JIC 37º ADAPTER
1-1/4" N.P.T. "OUT" PORT JIC 37º
"IN" PORT JIC 37º ADAPTER 1/4" N.P.T.
1-1/2" PIPE ADAPTER 1/4" N.P.T.

SUPPLY 1-1/2" HOSE

JIC 37º ADAPTER

1-1/2" N.P.T.
PIPE SIZE
(SEE CHART)
LUBRICATOR
1-1/2" RELAY NL-24-8
VALVE SRV150
#4 HOSE
NO. OF STARTERS MIN. PIPE SIZE
EXHAUST PIPED AWAY FOR GAS
2 2" #4 HOSE OR USE MUFFLER SS660-A674 OR
3 2-1/2" DEFLECTOR SM450-A375
4 3"
5 3-1/2"
JIC 37º ADAPTER
"OUT" PORT JIC 37º
1/4" N.P.T
"IN" PORT JIC 37º ADAPTER 1/4" N.P.T.
1-1/2" PIPE ADAPTER 1/4" N.P.T.

SUPPLY MUST BE ADEQUATE

TO MAINTAIN 120-150 PSIG 1-1/2" HOSE
AT THE STARTERS WITH THE
STARTERS RUNNING.
JIC 37º ADAPTER
1-1/2" N.P.T.

LUBRICATOR FOR NATURAL GAS OPERATION, STARTER MAIN EXHAUST

1-1/2" RELAY NL-24-8 MUST BE PIPED AWAY.
VALVE SRV150
TO PIPE THE DRIVE HOUSING VENT, REMOVE THE DRIVE
EXHAUST PIPED AWAY FOR GAS OR HOUSING PLUG AND REPLACE IT WITH A SUITABLE
USE MUFFLER SS660-A674 OR TUBING LINE. THE TUBING MUST VENT AT A SAFE
DEFLECTOR SM450-A375 LOCATION AND MUST NOT BE INTERCONNECTED WITH
ANY OTHER EXHAUST LINES WHICH MIGHT INTRODUCE A
BACK PRESSURE ON THE DRIVE HOUSING VENT.

(Dwg. TPA847-2)

How to Order a Starter

MODEL CODING FOR SS815, SS825 AND SS850 STARTERS

- MODEL CODING -
SS815 G B 03 R 31 - O 2 G
SS825 G C 03 R 31 - O 2 G
SIZE STARTER DRIVE HOUSING
TYPE STARTER EXHAUST
GEARING ORIENTATION CODE
DRIVE HOUSING INLET
ROTATION TYPE PINION
DRIVE

- MODEL CODING -
SS850 G D 09 R 51- O 2 E
SIZE STARTER DRIVE HOUSING
TYPE STARTER EXHAUST
GEARING ORIENTATION CODE
DRIVE HOUSING INLET
ROTATION TYPE PINION
DRIVE

(Dwg. TPD1495)

10 03531480_ed10
 62
29 46
37 47 32
41
40 35 28 45
42

03531480_ed10
(Dwg. TPA853-4)
39 53
15 27
9 59
51 23
3
8 22
61

5 21
60

10A
24
2 25
33
14 56 49
Front End Construction of Series SS850

26 30
57 45
31A 25
44
3 31 49 29
12 47 30
54 28
50 26
10
36 33
31
19
11
34
20
21
18 35
4A 16 58
4 6 13 17 27
1 7
22
SERIES SS815, SS825, AND SS850 STARTERS
(SS815 AND SS825 SHOWN IN FULL VIEW) 37
24
23
34
46 32
56
36
50 54 44 53

33A

11
12
(Dwg. TPA778-6)
3
12
11
10
4
4A 8
2
14 6
5
10A
36
37 6
9
1
50
49
15
34 40
35 42 44
45 7 16
51
26
Series SS815 and SS825 Starters Exploded Diagram

29 39
28 41 18
27 54 58
24 13
19
31 46
22 57 60
53 32 59
21 62
31A 30 25 33 17
23 47 20
56
61

03531480_ed10
Series SS815 and SS825 Starters Parts List
Item Part Description Part Number Item Part Description Part Number
1 Motor Housing 28 Drive Housing Cap Screw (8) SS800-744
with 2-1/2” Tapped Exhaust SS800-40 29 Drive Housing Cap Screw
with 2-1/2” SAEJ518C Lock Washer (8) CE210-605
Flanged Exhaust SS800-140 30 Drive Housing Kit SS825-K300
2 Motor Housing Cover Assembly †• 31 Drive Housing O-Ring SS800-244
with 1-1/2” Tapped Inlet SS800-A102 31A Drive Housing Vent Plug P250-546
with 1-1/2” SAEJ518C Flanged 32 Front Drive Shaft Bearing
Inlet SS800-A202 for SS815B Models SS800-363
3 Housing Cover Plug (3) HSSPPS-3 for SS825C Models SS850-363
4 Motor Housing Cover Cap Screw (4) SS800-25 † 33 Drive Housing Seal SS800-271
4A Motor Housing Cover Cap Screw † 34 Bulkhead Retainer SS800-181
Washer (4) SS800-26 35 Bulkhead Kit SS800-K150
5 Cylinder Kit SS800-K3 †• 36 Outer Bulkhead O-Ring SS800-152
† 6 End Plate Alignment Pin (2) 510-669A †• 37 Inner Bulkhead O-Ring SS800-151
† 7 Cylinder Alignment Pin SS800-99 † 39 Clutch Spring Cup Retainer SS800-366
†• 8 Cylinder O-Ring (4) SS800-67 40 Clutch Spring Cup SS800-367
9 Rear End Plate † 41 Clutch Spring SS800-583
for SS815RB or SS825RC Models SS800R-12 42 Clutch Jaw Kit
for SS800LB, SS815LB or for SS815RB or
SS825LC Models SS800L-12 SS825RC Models SS800R-K587
† 10 Rear Rotor Bearing SS800-24 for SS815LB or
†• 10A Rotor Shaft O-Ring C321-606 SS825LC Models SS800L-K587
†• 11 Rear Rotor Bearing O-Ring HRA20A-990 44 Front Drive Gear Bearing SS800-278
12 Rotor Clamp Nut SS800-65 45 Drive Gear Cup SS800-177
13 Rotor SS825-53 46 Drive Gear Lock Washer SS800-180
14 Rotor Clamp Nut Screw SS800-63 47 Large Drive Shaft Bearing Retainer SS800-107
†• 15 Vane Packet (set of 5 Vanes) SS800-42A-5 49 Piston Kit SS800-K703
16 Front End Plate SS800G-11 †• 50 Piston O-Ring SS800-337
17 Motor Wave Washer (2) SS800-224 †• 51 Piston Seal SS800-273
† 18 Front Rotor Bearing SS800-22 53 Drive Shaft Kit
19 Rotor Pinion Retaining Screw SS800-732 for SS815RB or
20 Rotor Pinion SS825RC Models SS800R-K8
for SS815RB, SS800LB or for SS815LB or
SS815LB Models SS800B-17 SS825LC Models SS800L-K8
for SS825RC or 54 Rear Drive Shaft Bearing Kit
SS825LC Models SS825C-17 (includes bearing and retainer) SS800-K399
• 21 Drive Pinion Retaining Screw 56 Piston Return Spring SS800-700
for SS815RB or SS825RC 57 Piston Return Spring Seat SS800-191
Models SS800R-394 58 Gear Case SS800-37
for SS815LB or SS825LC 59 Drive Gear Bearing Retainer SS800-361
Models SS800L-394 60 Drive Gear Shaft Bearing Retainer SS800-632
22 Drive Pinion Washer SS800-725 † 61 Rear Drive Gear Bearing SS800-359
• 23 Drive Pinion 62 Drive Gear
for SS815GB03R31 Models SS815R-13-31 for SS815108 or
for SS815GB03L32 Models SS815L-13-32 SS815LB Models SS815B-9
for SS815GB03R91 and for SS825RC or
SS825GC03R91 Models SS815R-13-91 SS825LC Models SS825C-9
for SS815GB03L92 and * Nameplate SS800-301
SS825GC03L92 Models SS815L-13-92 * Nameplate Screw (4) R4K-302
for SS825GC03R25 Models SS825R-13-25 * Relay Valve SRV150
for SS825GC03L26 Models SS825L-13-26 * Muffler SS660-A674
24 Pinion Spring Sleeve SS800-335 * Road Splash Deflector SM450-A735
† 25 Pinion Spring * Air Strainer SM450-A267AT
for SS800RB, SS815RB or * Lubricator HDL2
SS825RC Models SS800R-419 * In-Line Lubricator NL-24-8
for SS800LB, SS815LB or * Tune-up Kit (includes illustrated parts
SS825LC Models SS800L-419 6[2], 7, 8, 10, 10A[4], 11, 15, 18, 24, 25,
26 Drive Gear Screw SS800-179 27, 31, 33, 34, 36, 37, 39, 50,
†• 27 Drive Gear Screw O-Ring SS800-176 51, 60 and 61) SS800-TK2
* Not Illustrated
† Indicates Tune-up Kit part.
• To keep downtime to a minimum, it is desirable to have on hand certain repair parts. We recommend that you stock one (pair or set) of
each part indicated by a bullet (•) for every four tools in service.

03531480_ed10 13
14
(Dwg. TPA820-3)
3
12
11
10
4
4A 8
2
14 6
5
10A
36
37 6
9
1
50
49
Series SS850 Starters Exploded Diagram

15
34 40
35 42 44
45 7 16
51
26
29 39
28 41 18
27 54 58
24 13
46 19
31 22 60
53 32 59
33A 30 21 62
25 33 17

23 47 20

56
61

03531480_ed10
Series SS850 Starters Exploded Diagram
Item Part Description Part Number Item Part Description Part Number
1 Motor Housing 29 Drive Housing Cap Screw
with 2-1/2” Tapped Exhaust SS800-40 Lock Washer (8) CE210-605
with 2-1/2” SAEJ518C 30 Drive Housing Kit SS850-K300
Flanged Exhaust SS800-140 †• 31 Drive Housing O-Ring SS850-244
2 Motor Housing Cover Assembly 32 Front Drive Shaft Bearing SS850-363
with 1-1/2” Tapped Inlet SS800-A102 † 33 Drive Housing Seal SS850-271
with 1-1/2” SAEJ518C Flanged 33A Drive Housing Vent Plug P250-546
Inlet SS800-A202 34 Bulkhead Retainer SS500-181
3 Housing Cover Plug (3) HSSPPS-3 35 Bulkhead Kit SS850-K150
4 Motor Housing Cover Cap Screw (4) SS800-25 †• 36 Outer Bulkhead O-Ring SS850-152
4A Motor Housing Cover Cap Screw †• 37 Inner Bulkhead O-Ring SS805-151
Washer (4) SS800-26 † 39 Clutch Spring Cup Retainer SS850-366
5 Cylinder Kit SS800-K3 40 Clutch Spring Cup SS850-367
† 6 End Plate Alignment Pin (2) 510-669A † 41 Clutch Spring SS850-583
† 7 Cylinder Alignment Pin SS800-99 42 Clutch Jaw Kit
†• 8 Cylinder O-Ring (4) SS800-67 for SS850RD Models SS800R-K587
9 Rear End Plate for SS850LD Models SS800L-K587
for SS850RD Models SS800R-12 44 Front Drive Gear Bearing SS800-278
for SS850LD Models SS800L-12 45 Drive Gear Cup SS800-177
† 10 Rear Rotor Bearing SS800-24 46 Drive Gear Lock Washer SS800-180
†• 10A Rotor Shaft O-Ring C321-606 47 Large Drive Shaft Bearing Retainer SS850-107
†• 11 Rear Rotor Bearing O-Ring HRA20A-990 49 Piston Kit SS850-K703
12 Rotor Clamp Nut SS800-65 †• 50 Piston O-Ring SS850-337
13 Rotor SS825-53 †• 51 Piston Seal SS800-273
14 Rotor Clamp Nut Screw SS800-63 53 Drive Shaft Kit
†• 15 Vane Packet (set of 5 Vanes) SS800-42A-5 for SS850RD Models SS850R-K8
16 Front End Plate SS800G-11 for SS850LD Models SS850L-K8
17 Motor Wave Washer (2) SS800-224 54 Rear Drive Shaft Bearing Kit
† 18 Front Rotor Bearing SS800-22 (includes bearing and retainer) SS850-K399
19 Rotor Pinion Retaining Screw SS800-732 56 Piston Return Spring SS850-700
20 Rotor Pinion 58 Gear Case SS850-37
for SS850RD or SS850LD Models SS850D-17 59 Drive Gear Bearing Retainer SS800-361
• 21 Drive Pinion Retaining Screw 60 Drive Gear Shaft Bearing Retainer SS800-632
for SS850RD Models SS850R-394 † 61 Rear Drive Gear Bearing SS800-359
for SS850LD Models SS850L-394 62 Drive Gear SS850D-9
22 Drive Pinion Washer SS800-725 * Nameplate SS800-301
• 23 Drive Pinion * Nameplate Screw (4) R4K-302
for SS850GD09R51 and * Relay Valve SRV150
SS850FGD09R51 Models SS850R-13-51 * Muffler SS660-A674
for SS850GD09L52 and * Road Splash Deflector SM450-A735
SS850FGD09L51 Models SS850L-13-52 * Air Strainer SM450-A267AT
† 24 Pinion Spring Sleeve SS800-335 * In-Line Lubricator NL-24-8
† 25 Pinion Spring * Lubricator HDL2
for SS850RD Models SS850R-419 * Tune-up Kit (includes illustrated parts
for SS850LD Models SS850L-419 6[2], 7, 8, 10, 10A[4], 11, 15, 18, 24, 25,
26 Drive Gear Screw SS800-179 27, 31, 33, 34, 36, 37, 39, 50,
†• 27 Drive Gear Screw O-Ring SS800-176 51, 60 and 61) SS850-TK2
28 Drive Housing Cap Screw (8) SS800-744
* Not illustrated.
† Indicates Tune-up Kit part.
To keep downtime to a minimum, it is desirable to have on hand certain repair parts. We recommend that you stock one (pair or set) of
•
each part indicated by a bullet (•) for every four tools in service.

03531480_ed10 15
Maintenance, Disassembly / Assembly Instructions

WARNING
Always wear eye protection when operating or performing any maintenance on this starter. Always turn off the air
supply and disconnect the air supply hose before installing, removing or adjusting any accessory on this starter or
before performing any maintenance on this starter.

Lubrication
Each time a Series SS815, SS825 or SS850 Starter is 4. Lubricate the inside diameter of the Drive Shaft (53) with
disassembled for maintenance or repair, lubricate the starter Ingersoll Rand No. 130 Grease.
as follows: 5. Lubricate the Front Drive Gear Bearing (44) with
For temperatures above 32°F (0°C), use a good quality Ingersoll Rand No. 130 Grease.
SAE 10 non-detergent motor oil. 6. Lubricate the pinion end of the Drive Shaft with
For temperatures below 32°F (0°C), use diesel fuel. Ingersoll Rand No. 11 Grease.
7. Wipe a thin film of Ingersoll Rand No. 130 Grease in the
1. Lubricate all O-Rings with O-Ring lubricant. bore of the Drive Housing (58).
2. Lubricate the Drive Gear (62) with 8 oz. of 8. Roll the Piston Return Spring (56) in Ingersoll Rand
Ingersoll Rand No. 130 Grease. No. 130 grease.
3. Lubricate the Vanes (15) with 10W non-detergent oil. 9. Coat the outside of the Piston (49) with Ingersoll Rand
No. 130 Grease.

Disassembly
General Information
1. Do not disassemble the starter any further than WARNING
necessary to replace worn or damaged parts. Failure to follow this procedure could result in injury to
2. When grasping a part in a vise, always use personnel.
leather-covered or copper-covered vise jaws to protect
the surface of the part and help prevent distortion. This is 10. Place the Drive Housing in an arbor press, piston end up.
particularly true of threaded members. Apply pressure to the Piston (49) to compress the Piston
3. Do not remove any part which is a press fit in or on a Return Spring (56) before removing the Bulkhead
subassembly unless the removal of that part is necessary Retainer (34).
for replacement or repairs. 11. Using a screwdriver, remove the Bulkhead Retainer.
4. Always have a complete set of seals and O-Rings on Ease off the arbor press.
hand before starting any overhaul of a starter. Never
reuse old seals or gaskets.
5. Always mark adjacent parts on the Motor Housing Cover
CAUTION
(2), Motor Housing (1), Gear Case (58) and Drive Make sure the tension of the spring pushes the Bulkhead
Housing (30) so these members can be located in the out of the Drive Housing before removing the Drive
same relative position when the Starter is reassembled. Housing from the arbor press.
Drive Housing
12. Remove the Bulkhead (35) from the Piston.
1. Remove the rear Motor Housing Cover Plug (3) from the 13. Remove the Outer Bulkhead O-Ring (36) and the Inner
rear of the Motor Housing Cover (2). Bulkhead O-Ring (37).
2. Grasp the Drive Pinion (23) in a vise with the Starter 14. Slide the Drive Shaft (53) from the Drive Housing.
supported on the workbench. 15. Pull the Piston Return Spring (56) off the Drive Shaft.

NOTICE NOTICE
Models SS815RB, SS825RC and SS850RD have a Do not remove the Front Drive Shaft Bearing (32) or the
left-hand thread; Models SS815LB, SS825LC and Drive Housing Seal (33) unless replacement is necessary
SS850LD have a right hand thread. and new parts are available. The Bearing and/or the Seal
will always be damaged when removed from the Drive
3. Using a wrench, remove the Drive Pinion Retaining Housing.
Screw (21).
4. Remove the starter from the vise. 16. Remove the Piston O-Ring (50) from the Piston.
5. Remove the Drive Pinion Washer (22) and the Drive
Pinion (23).
6. Slide the Pinion Spring Sleeve (24) and the Pinion Spring
NOTICE
(25) off the Drive Shaft. The following operation will damage the Piston Seal (51).
7. Insert a 3/8” square drive extension through the Motor Therefore, always have a replacement Seal on hand.
Housing Cover to hold the Rotor (13) from turning. Using
a 5/16” (8 mm) x 8” (203 mm) long hex wrench inserted 17. Insert a large screwdriver blade through the Piston Seal
into the end of the Drive Shaft, unscrew the Drive Gear so that it rests on top of the Clutch Spring Cup. Pry the
Screw (26). Seal out of the Piston.
8. Unscrew and remove the Drive Housing Cap Screws (28) 18. Press the Clutch Spring Cup (40) down and remove the
and Lock Washers (29). Clutch Spring Cup Retainer (39).
9. Tap the Drive Housing (30) with a plastic hammer to help 19. Remove the Clutch spring Cup and Clutch Spring (41).
dislodge it from the Gear Case (58). 20. Remove the two Clutch Jaws (42).

16 03531480_ed10
21. Remove the Front Drive Gear Bearing (44), Drive Gear 8. Remove and examine each Vane (15). Install a new set
Cup (45), Drive Gear Lock Washer (46), Drive Gear of Vanes if any Vane is cracked, spalled or worn to the
Screw O-Ring (27) and Drive Gear Screw (26). extent that its width is 15/16” (24 mm) or less at either
22. Using a screwdriver, remove the Large Drive Shaft end.
Bearing Retainer (47). 9. Grasp the Rotor in a vise. Using a 5/32” (4 mm) hex
23. Press the Rear Drive Shaft Bearing and Drive shaft (53) wrench, loosen the Rotor Clamp Nut Screw (14).
out of the Piston. If the Rear Drive Shaft Bearing needs to Unscrew and remove the Rotor Clamp Nut (12).
be replaced, proceed as follows: 10. Remove the Large Rear Rotor Bearing O-Ring (11).
a. Using a small chisel, cut and remove the small drive 11. Remove the Rear End Plate (9) from the rotor shaft.
shaft bearing retainer on the Drive Shaft. 12. Remove the Small Rear Rotor Bearing O-Ring (10A) from
b. Press the Rear Drive Shaft Bearing (54) off the Drive the rotor shaft.
Shaft. 13. If the Rear Rotor Bearing (10) needs to be replaced,
Motor Housing remove it from the Rear End Plate.
14. Push the Cylinder (5) out of the Motor Housing.
1. Unscrew and remove the Motor Housing Cover Cap 15. Remove the Cylinder O-Rings (8) from the Cylinder.
Screw (4).
2. Pull the Motor Housing Cover (2) from the motor Housing Gear Case
(1). It may be necessary to dislodge the Motor Housing 1. Place the Gear Case (58) on a workbench.
Cover by tapping it with a plastic hammer. 2. Using retaining ring pliers and working through the
3. Tap the Gear Case (58) with a plastic hammer to dislodge access holes in the gear web, remove the Drive Gear
it from the Motor Housing. Bearing Retainer (59).
4. Grasp the Rotor Pinion in a vise and using a wrench, 3. Pull the Drive Gear (62) out of the Gear Case.
remove the Rotor Pinion Retaining Screw (19). 4. Do not disassemble the Drive Gear of Series SS815,
5. Remove the Rotor Pinion (20) from the rotor shaft. SS825 or SS850. If the Drive Gear is defective, install a
6. Slide the Front End Plate (16), Front Rotor Bearing (18) new or factory rebuilt unit.
and Motor Wave Washers (17) off the rotor shaft. 5. Using a retaining ring pliers, remove the Drive Gear Shaft
7. Remove the Rotor (13) and Rear End Plate (9) from the Bearing Retainer (60).
Cylinder. 6. Remove the Rear Drive Gear Bearing (61) from the Drive
Gear.

Assembly
General Instructions 4. Install the Rear End Plate (9), bearing end up, onto the
rotor shaft.
1. Always press on the inner ring of a ball-type bearing
when installing the bearing on a shaft. 5. Screw the Rotor Clamp Nut (12) onto the rotor shaft with
the shoulder toward the bearing. Tighten the nut until
2. Always press on the outer ring of a ball-type bearing
there is .001” (.02 mm) to .003” (.07 mm) clearance
when pressing the bearing into a bearing recess.
3. Whenever grasping a starter or part in a vise, always use between the Rear End Plate and Rotor.
6. Using a 5/32” (4 mm) hex wrench, tighten the Rotor
leather-covered or copper-covered vise jaws. Take extra
Clamp Nut Screw (14). After tapping the End Plate away
care with threaded parts or housings.
4. Except for bearings, always clean every part and wipe from the rotor face with a plastic hammer, recheck the
clearance between the Rear End Plate and Rotor.
every part with a thin film of oil before installation.
5. Check every bearing for roughness. If an open bearing 7. Check the two End Plate Alignment Pins (6). If they are
must be cleaned, wash it thoroughly in a suitable bent or broken, remove them from the Cylinder and press
cleaning solution and dry with a clean cloth. Sealed or in a new pin or pins.
shielded bearings should never be cleaned. Work 8. Check the Cylinder Alignment Pin (7). If it is bent or
grease thoroughly into every open bearing before broken, remove it from the Cylinder and press in a new
installation. pin.
6. Apply a film of O-Ring lubricant to all O-Rings before final 9. Using O-Ring lubricant, lubricate and install the two
assembly. inside Cylinder O-Rings (8).
10. Position the Motor Housing (1) vertically, on two blocks of
Gear Case wood, locating slot up.
1. Place the Drive Gear Bearing Retainer (59) over the rear 11. Using a plastic hammer, tap the Cylinder (5) into the
end of the Drive Gear. Motor Housing making sure the Cylinder Alignment Pin
2. Using an arbor press, press the Rear Drive Gear Bearing (7) seats into the slot of the Motor Housing.
(61) onto the rear end of the Drive Gear. 12. Using O-Ring lubricant, lubricate and install the two
3. Using retaining ring pliers, install the Drive Gear Shaft outside Cylinder O-Rings (8).
Bearing Retainer (60). 13. For Right-Hand Rotation Starter: Insert the Rotor (13)
4. Position the Gear Case on a workbench. Using a plastic into the Cylinder, pinion end toward the Cylinder
hammer, seat the Rear Drive Gear Bearing into the Gear Alignment Pin.
Case by tapping the opposite end of the Drive Gear.
5. Using retaining ring pliers and working through the NOTICE
access holes in the gear web, install the Drive Gear
Bearing Retainer (59). Make sure the protruding End Plate Alignment Pin (6) in
6. Lubricate the Drive Gear with approximately 8 oz. the Cylinder aligns with the dowel hole in the Rear End
(240 mL) of Ingersoll Rand No. 130 Grease. Plate (9) numbered SS800R-12. Make sure the air ports of
both the Cylinder and the Rear End Plate align.
Motor Housing
1. Clamp the Rotor in a vise threaded end up. For Left-Hand Rotation Starter:
2. Install the Rear Rotor Bearing (10) into the Rear End Insert the Rotor (13) into the Cylinder, pinion end away from
Plate. the Cylinder Alignment Pin.
3. Using O-Ring lubricant, lubricate and install the Small
Rear Rotor Bearing O-Ring (10A) onto the rotor shaft
until it butts against the rotor shaft shoulder.

03531480_ed10 17
 9. Press the inserted parts into the Drive Shaft, and install
NOTICE the Clutch Spring Cup Retainer (39).
10. Using an arbor press, press the Piston Seal (51), cover
Make sure the protruding End Plate Alignment Pin (6) in side out, into the Piston until it is flush with the piston face.
the Cylinder aligns with the dowel hole in the Rear End 11. Install the Piston (49) onto the Drive Shaft until the Rear
Plate (9) numbered SS800L-12. Make sure the air ports of Drive Shaft Bearing seats into the Piston.
both the Cylinder and the Rear End Plate align. 12. Using a thin flat blade screwdriver to assist in this
operation, coil the Large Drive Shaft Bearing Retainer
14. Lightly lubricate each Vane (15) and insert one in each of (47) into the groove of the Piston to retain the outer race
the rotor vane slots. of the Drive Shaft Bearing.
15. Slide the Front End Plate (16) over the pinion end of the 13. Lubricate the Piston O-Ring (50) and install it in the
Rotor. The other protruding End Plate Alignment Pin (6) groove of the Piston.
in the face of the Cylinder should align with the dowel 14. Position the Drive Housing in an arbor press, pinion end
hole in the Front End Plate. down and install the Drive Housing Seal (33) into the
16. Insert the two Motor Wave Washers (17) into the Front Drive Housing.
End Plate well.
17. Install the Front Rotor Bearing (18) into the Front End
Plate well.
NOTICE
18. Install the Rotor Pinion (20) on the rotor shaft so that the Press the Seal into the Drive Housing so that the lip of
lugs on the Pinion engage those on the shaft. the Seal faces away from the Drive Pinion.
19. Screw the Rotor Pinion Retaining Screw (19) into the
rotor shaft and tighten to 90 ft-lb (122 Nm) torque. 15. Using a sleeve that contacts the outer race of the Front
20. Using O-Ring lubricant, lubricate and install the Rear Drive Shaft Bearing (32), press the Bearing into the Drive
Rotor Bearing O-Ring (11) onto the Rear Rotor Bearing. Housing until it seats. For Models SS815 and SS825,
21. Check freeness of the motor by turning the Rotor Pinion. drop the Piston Return Spring Seat (57) on top of the
If necessary, tap the Front End Plate with a soft hammer Front Drive Shaft Bearing.
to align the motor. 16. Slide the Piston Return Spring (56) onto the Drive Shaft
22. Align the punch marks on the Gear Case (58), Motor and snap it into the front of the Piston so that it is against
Housing (1) and Motor Housing Cover (2) and assemble the Large Drive Shaft Bearing Retainer (47).
as follows: 17. Lubricate and insert the assembled Drive Shaft into the
a. Grasp the Gear Case (58) in a vise by the Drive Gear Drive Housing.
Shaft. 18. Using O-Ring lubricant, lubricate and install the Outer
b. Insert the pinion end of the motor into the Gear Case. Bulkhead O-Ring (36) and the Inner Bulkhead O-Ring
Using a soft hammer, tap the Motor Housing (1) until it (37) on the Bulkhead (35).
seats. 19. Slide the Bulkhead onto the Piston.
c. Position the Motor Housing Cover (2) on the Motor 20. With the Drive Housing in the arbor press, press down on
Housing. Using a soft hammer, tap the Motor Housing the rear face of the Piston.
Cover until it is seated on the Motor Housing.
NOTICE
NOTICE
Feel the underside of the Drive Housing to make sure the
Screw a 12” (305 mm) piece of 1-1/2” (38 mm) pipe into Drive Shaft passes through the Bearing.
the air inlet to act as a handle to help align the Motor
Housing with the Motor Housing Cover and Gear Case. Using a screwdriver, install the Bulkhead Retainer (34).

d. Lubricate the threads and install the Motor Housing

Cover Cap Screws (4) and Lock Washers (4A), WARNING
alternately tightening each a little at a time to a final
torque of 60 ft-lb (81.4 Nm). Make sure the Bulkhead Retainer is properly seated in the
23. Install two of the Housing Cover Plugs (3) into the Motor Motor Housing groove before easing off the arbor press.
Housing Cover inlet boss and tighten securely.
21. Remove the Drive Housing from the arbor press.
Drive Housing 22. Using O-Ring lubricant, lubricate and install the Drive
1. Press the Rear Drive Short Bearing (54) onto the Drive Housing O-Ring (31) in the groove of the Drive Housing.
Shaft. 23. Position the assembled Motor Housing and Gear Case
2. Slide the small bearing retainer, convex side first, onto on a workbench. Assembled unit must be upright to
the Drive Shaft. Press it into position in accordance with accept the Drive Housing.
the instructions packaged with the new Retainer. 24. Carefully position the assembled Drive Housing (30) on
3. Assemble the Drive Gear Screw (26), Drive Gear Lock to the Gear Case so as not to damage the Piston Seal.
Washer (46), Drive Gear Cup (45) and Drive Gear Screw Align the punch marks of the Gear Case and Drive
O-Ring (27). Housing.
4. Grasp the Drive Shaft (53) in a vise, pinion end down. 25. Install the Drive Housing Cap Screw Lock Washers (29)
Place assembled Drive Shaft Screw Unit into the Drive and the Drive Housing Cap Screws (28) and tighten to 28
Shaft, screw and head down. Lubricate the inside ft-lb (38 Nm) torque.
diameter of the Drive Shaft with Ingersoll Rand 26. Insert a 3/8” (10 mm) square drive extension bar through
No. 130 Grease. the hole in the Motor Housing Cover to prevent the Rotor
5. Slide the Front Drive Gear Bearing (44) into the Drive from turning. Using a 5/16” (8 mm) x 8” (203 mm) long
Shaft. hex wrench inserted into the end of the Drive Shaft,
6. Lubricate with Ingersoll Rand No. 130 Grease and install tighten the Drive Gear Screw (26) to 29 ft-lb (39.3 Nm)
the Driving Clutch Jaw teeth facing up and Driven Clutch torque.
Jaw teeth facing down into the Drive Shaft. 27. Using Ingersoll Rand No. 11 Grease, Lubricate and slide
7. Insert the Clutch Spring (41) into the Drive Shaft. the Pinion Spring (25) and the Pinion Spring Sleeve (24)
8. Insert the Clutch Spring Cup (40) into the Drive Shaft. over the Pinion end of the Drive Shaft.

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28. Lubricate the pinion end of the Drive Shaft with
Ingersoll Rand No. 11 Grease and install the Drive NOTICE
Pinion (23).
29. Grasp the Drive Pinion in a vise with the Starter Models SS815RB, SS825RC and SS850RD have a
supported on a workbench. left-hand thread; Models SS815LB, SS825LC and
30. Place the Drive Pinion Washer (22) onto the Drive Pinion SS850LD have a right-hand thread.
Retaining Screw (21). Install the Drive Pinion Retaining
Screw into the end of the Drive Shaft and tighten it to Remove the Starter from the vise.
80 ft-lb (108.5 Nm) torque for SS815 and SS825 Starters,
and 125 ft-lb (169.5 Nm) torque for SS850 Starters. 31. Install the rear Motor Housing Cover Plug (3) and tighten
securely.

Test and Inspection Procedure

1. Clutch Ratcheting: Turn the Drive Shaft Pinion (23) by (69.0 + 2.0 mm) for Models SS815, SS825 and 8-3/4”
hand in the direction of Starter rotation. The clutch should (222 + 2.0 mm) for Model SS850. Remove the pressure
ratchet smoothly with a slight clicking action. from the “In” Port. Measure the distance from the face of
2. Motor and Gearing Freeness: Turn the Drive Shaft the Drive Shaft Pinion (23) to the face of the mounting
Pinion (23) opposite the direction of Starter rotation. The flange. It should be 1-25/32” 45.0 + 2.0 mm) for Models
Drive Shaft Pinion should turn by hand. SS815, SS825 and 7-3/32” (180 + 2.0 mm) for Model
3. Pinion Engagement: Apply 50 psig (3.4 bar/345 kPa) SS850.
pressure to the engagement “In” Port. Drive Shaft Pinion 4. Motor Vane Action: Apply 90 psig (6.2 bar/620 kPa)
(23) should move outward and air or gas should escape pressure using a 3/8” (9 mm) supply line to the inlet of the
from the “Out” Port. Plug the “Out” Port and apply motor. Starter should run smoothly.
150 psig (10.3 bar/I 034 kPa) pressure to the “In” Port. 5. Motor Seals: Plug the exhaust and apply 20 psig
Check and make sure no air or gas is escaping. Measure (1.4 bar/138 kPa) pressure to the inlet of the motor.
the dimension from the face of the Drive Shaft Pinion (23) Immerse the Starter for 30 seconds in a nonflammable
to the face of the mounting flange. It should be 2-23/32” solvent. If the Starter is properly sealed, no bubbles, will

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Troubleshooting Guide
Trouble Probable Cause Solution
Motor will not run No air supply. Check for blockage or damage to air supply linesor tank.
Inspect Motor Assembly and power train and repair or
Damaged Motor Assembly
replace if necessary.
Foreign material in Motor and/or Remove Motor Assembly and/or piping and remove
piping blockage.
Blocked exhaust system. Remove Housing Exhaust Cover and check for blockage.
Defective Control Valve or Relay
Replace Control Valve or Relay Valve.
Valve.
Loss of Power Low air pressure to Starter. Check air supply.
Restricted air supply line. Check for blockage or damage to air lines.
Relay Valve malfunctioning. Clean or replace lines or Relay Valve. Lube Relay Valve.
Exhaust flow restricted. Check for blocked or damaged piping. Clean or replace
piping. Check for dirt or foreign material and clean or
remove. Check for ice build-up. Melt ice and reduce
moisture build-up to Starter.
Damaged Motor Assembly. Replace Motor Assembly.
Foreign material in Starter Drive. Remove obstruction.
Damaged or worn Drive parts. Check Drive components and replace if necessary.
Inadequate lubrication. Check the lubricator, inlet hose, fitting, and oil supply hose
to make sure they are vacuum tight and free of leaks.
Tighten all joints and replace lubricator if necessary.
Starter drive does not Clogged control hoses. Remove the control hoses attached to the Drive Housing
engage ring gear or and clean them by blowing compressed air through them.
engages and disengages
ring gear very slowly. WARNING
Firmly secure the hose end before turning on the air.
Make certain no one is in line with the discharge end of
the control hose.
Clogged or faulty Control Valve. Remove and inspect the Control Valve or install a new
Control Valve if necessary.
Broken Clutch Jaws or other parts. Disassemble Drive Housing and replace broken parts.
Motor runs, pinion Broken Shaft, Gearing, or Clutch Disassemble Drive Housing and replace broken parts.
engages but does not Jaws.
rotate.
Excessive butt Dry Drive Pinion Spline. Remove Drive Pinion and lubricate the Drive Pinion and
engagements. the helical spline of the Drive Shaft. Refer to Disassembly
of the Drive Housing.

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Notes

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Notes

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Notes

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